Mono-material divider block assembly

ABSTRACT

The invention is directed to a divider block assembly made from one piece of material. Traditional divider blocks require modular sections so that piston alignment can be calibrated precisely. The current invention uses replaceable pistons and sleeves that are suitable for use at high fluid pressures. The use of these pistons also allows for a single, bodied, one-piece, metal divider body, rather than the conventional multiple block divider blocks, which allows for a more efficient manufacturing method and stronger, more reliable, and more efficient lubricant dispensing system. The use of any of these aspects separately can improve performance, and not all are required in every embodiment.

This application is a Continuation of U.S. application Ser. No.15/297,131, filed Aug. 18, 2016, which claims priority from U.S.application Ser. No. 14/171,434 filed Feb. 3, 2014, both of which arehereby incorporated by reference.

TECHNICAL FIELD OF THE INVENTION

The present invention relates to a divider block assembly that is madefrom one material, such as steel. Other than this invention, there is nocurrent technology that enables anyone to make a complicated lubricationsystem (with the sophistication and exactness that is required in highperformance industries) without breaking the lubrication system intomodules. Technology involving divider blocks have not changed much inthe last 75 years. For example, a lubricating system patent that waspublished in Jan. 27, 1953 shows a divider block, (the term “dividerblock” is to be used interchangeably with “divider valve” and“distribution block” that is used in the industry) having U.S. Pat. No.2,766,847 issued to Harter and assigned to Trabon Engineering Corp(“Trabon”). Trabon currently manufactures a divider block that is verysimilar to technology that was developed in the mid-1900's. And a searchin respective patent classification (both US and internationally) showsvery little progress made in this field. FIG. 1 shows Trabon's patentfigure showing the lubrication system and is marked as “prior art.”

FIG. 2 shows a current model of a divider block currently sold by Trabonand sold as Trabon® MSP Modular Divider Valves. The manual for thismodel is L10102 and is available atwww.graco.com/content/dam/graco/led/literature/flyers/110102/L10102EN-B.pdf.Going back to FIG. 1, this particular prior art system discloses aflow-reversing valve 33 that includes a piston 41 adapted to move fromone end of the cylinder 36 to the other end for reversing the directionof the flow. See FIG. 1. Comparing this system with the current systemin FIG. 2, the divider block 200 has modular sections 201. The modularsections each have pistons (not shown) in end of the ends 202. Thesepistons are not much different than the pistons disclosed in FIG. 1.

The current system is dependent on modular sections. There are manyreasons why traditional divider blocks require modular sections. Thefirst reason is because these lubrication systems require high levels ofproficiency at high speeds and the modular sections allow for themanufacture of internal components and alignment of the pistons in aprecise manner. Industrial tools and machines, such as compressors, relyon proper lubrication, to ensure the proper operation and longevity ofcomponents. Without proper lubrication internal components risk seriousdamage. The divider block allows pressurized lubricant to distribute tomultiple lubrication points. In traditional divider blocks, thepressurized lubricant causes a set of pistons to move back and forthwithin the piston bores. The moving pistons open and close internalfluids channels, which allows the user to know the precise volume offluid that is distributed in the multiple outlet channels. Because thepistons in the divider block are powered by the pressure of the fluidbeing distributed, no additional source of power is necessary to operatethe divider block. These are the divider blocks shown in prior art U.S.Pat. in FIG. 1 and the Trabon model that is currently available.

As shown in FIG. 3, a typical prior art MJ series divider block 300consists of an inlet section 301 and three to eight valve sections 302.Each single section 302 can have an outlet on either side but the outleton one side must be plugged for the section to operate properly. Thereare two manifold bolts 303, 304 that run from the top to the bottomthrough each of the divider blocks. Each divider block section 305includes an internal piston (not shown) within a bore (not shown). Themanifold bolts 303, 304 connect each of the divider blocks 305. Theseblocks are held and sealed with gaskets between the inlet, ends, andbetween each block. The precise manufacture of the internal piston andthe valve sections require that the manufacture of these components bemade is sections and assembled and tested. The traditional methods ofmanufacture require the alignment of the pistons for each modularsection. The traditional methods of manufacture and using divider blocksrequire modular sections so that the pistons can be positioned andaligned.

Because these blocks are held together in multiple pieces or sections,the amount of pressure that can be held in the valves is about 3500 psi.During use, if any problems persisted in any of the blocks, the user isfirst required to remove the tubing from the divider block. Then, theuser is required to remove the complete block assembly from thecompressor. Next, the user must disassemble and replace the problemblock(s).

This type of assembly eventually led to the innovations of baseplates306 and manifold bolts 303, 304. Base plate section 306 includesinternal channels (not shown) for fluid movement and holes for movingfluid between adjacent sections. Each base plate section 306 alsoincludes an outlet (not shown) for dispensing the fluid, and holes formoving fluid in and out of the corresponding divider block sections 305.

One of the problems with the use of multiple divider block sections isthat with time the variations of pressure put on different parts of thedivider block assembly eventually wears out the divider block. Forexample, the manifold bolts 103, 104 are deliberately placed outside thecenter line of the divider block section 105, because centered boltholes would interfere with internal fluid passages. But with tighteningof the mounting fasteners and the end plugs, there are changes in thedivider blocks that will eventually result in faulty and imprecisedelivery of lubricants. The current mounting fasteners have specificdirections to not overturn the screws [not shown]. These mountingfasteners are frequently overturned by users, however, which results ineventual crushing or egg-shaping of the piston bore because of thevariation in pressure that results with overturned mounting fastenersThe bolts that go through the divider block when overtightened willdistort the cylindrical hole that runs lengthwise in the divider block.The precisely drilled hole then becomes egg shaped and causes the pistonbore to wear out prematurely or fail immediately. When the bore isegg-shaped it allows lubricant to flow around the piston to the point ofleast resistance injecting too much lubricant in some areas and starving(reducing) the needed oil in other areas.

What is needed is a lubrication system that allows for higher amounts ofpressure in the valves and in the whole system. What is needed is a wayto view traditional divider block models and question why they are builtin modular sections. What is needed is a way to prevent wear of thesedivider blocks when users over-tighten screws or change settings withinthe system.

SUMMARY OF THE INVENTION

An object of the invention is to provide a divider block assembly thatis stronger, more efficient, and capable of being repaired upon anyfailure to the system. Currently, there are no divider blocks in theindustry that can be repaired. All of them must be replaced with a newvalve section when the piston to bore clearance becomes excessivelyworn. An object of the invention is to make these divider blocksrepairable.

Another object of the invention is to provide an innovative method ofdelivering lubricants by using a divider block made substantially fromone material and in one piece, such as steel, which alters the flow oflubricant in the divider block in a surprisingly beneficial manner.

Another object of the invention is to provide a new method ofmanufacturing and using one divider block made from one piece and onematerial.

Another object of the invention is to eliminate the need for O-ringseals which become hardened and fail with extensive service in hightemperature applications and disintegrate with exposure to certain typesof lubricants.

Another object of the invention is to overcome the challenges of precisealignment of pistons by adding a replaceable sleeve to the system, whichholds pistons that are already aligned with the sleeves. These sleevescontain ends that connect with end plugs so that when the user turns theends, the sleeves get exactly aligned with the flow path. With this newdesign the end user cannot distort the piston bore because there are nomounting bolts to over tighten.

The embodiments of the current invention disclose a high pressuredivider block assembly that is capable of being used under highpressure.

The embodiments of the current invention disclose a replaceable sleeveand piston assembly that acts to replace the traditional pistons withinthe divider block. By adding this replaceable sleeve to the currentdivider block system, the end user does not have to replace the completedivider block when a piston becomes worn. Sleeves will act to bring thedivider block back to new condition in lieu of replacing the completetraditional modular sections.

The embodiments of the current invention disclose a lubricant deliveryassembly made from one material and one piece, such as one piece ofsteel. Such an assembly can use a replaceable sleeve and piston systemthat allows for the manufacture and use of a divider block in such amanner.

The foregoing has outlined rather broadly the features and technicaladvantages of the present invention in order that the detaileddescription of the invention that follows may be better understood.Additional features and advantages of the invention will be describedhereinafter. It should be appreciated by those skilled in the art thatthe conception and specific embodiments disclosed may be readilyutilized as a basis for modifying or designing other structures forcarrying out the same purposes of the present invention. It should alsobe realized by those skilled in the art that such equivalentconstructions do not depart from the spirit and scope of the inventionas set forth in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more thorough understanding of the present invention, andadvantages thereof, reference is now made to the following descriptionstaken in conjunction with the accompanying drawings, in which:

FIG. 1 is a perspective of a prior art divider block.

FIG. 2 is a perspective of a more recent prior art divider block.

FIG. 3 is a side view of a prior art divider block showing multiplesections.

FIG. 4 is side perspective of one embodiment of the current inventionshowing a mono-block.

FIG. 5 is an x-ray perspective of one embodiment of the currentinvention showing a mono-block.

FIG. 6 is a close-up perspective of the piston and sleeve that isutilized in one embodiment of the current invention.

FIG. 7A-C illustrates an embodiment in accordance with the inventionthat shows the sleeve interchangeability.

FIG. 8 shows a close up of a replaceable sleeve in accordance withembodiments of the current invention.

FIG. 9 illustrates the alignment of the sleeve system in accordance withembodiments of the current invention.

FIG. 10 shows an embodiment of the current system in accordance withembodiments of the current invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The current invention allows for the use of a divider block made fromone piece and one material. This “mono-block” (trademark pending)divider block introduces a new type of technology using replaceable andalignable sleeves. FIG. 4 shows a divider block 400 in accordance withone embodiment of the current invention. As shown by the body 401, thedivider block is made from a single integral and gapless continuouspiece of material. Although at first blush, it may seem that theinvention is only making separate, traditional elements into oneintegral piece, such is not the case. Such integration havetraditionally not been patent worthy, but the prior art is significantlydifferent. The inventor in the current case is eliminating the need tocalibrate each of the pistons, which led to the multiple segregation ofthe modular pieces in the first place. The prior art also is perceivedwith challenges to make a divider block with higher and highercapabilities to deliver precise amounts of lubricant. The mono-blockallows a user to achieve pressures much higher than 3500 psi, which hasbeen considered the capable modern limit. According to embodiments ofthe current invention, pressures as high as 10,000 psi is capable withthe monoblock divider.

The manufacture of a one piece assembly has surprising and potentiallycommercially-significant benefits. Because the manufacture of thedivider blocks can be made from one material, such as carbon steel orstainless steel, the use of traditional O-rings is removed. The removalof O-rings reduces a large percentage of the errors that often resultwith traditional divider blocks. The use of modular sections alsorequired a sophisticated maze of lubrication pathways so that eachmodular section matches exactly with another. By making a mono-block,these lubrication pathways are shorter and much more efficient (notshown and subject to design patents).

Other materials are contemplated for the mono-block assembly, includingbut not limited to, aluminum, magnesium, copper, tin, zinc, lead alloy,graphite and other composite materials. Because the process involves themanufacture of only one piece made from one material, different andsimpler processes to manufacture the divider blocks are contemplated,such as the ability to use special molds (or moulds) and castingprocesses. Although it is one piece and generally one material, morethan one alloy can be used in the manufacture of a one piece dividerblock. The divider block 400 can be made from a permanent mold castingmethods and forging methods that are used for current manufacture ofautomobile pistons or internal combustion engine pistons.

FIG. 5 shows an X-ray view of the mono-block 500 in accordance with oneembodiment of the current invention. The system includes replaceablesleeves 501 that are calibrated precisely to hold and align pistons 502within its body. The sleeves 501 and the pistons 502 allow for theinterchangeability of these components without having to dissemble anyof the modular sections. In the past, when any of the pistons provedfaulty, the whole divider block required disassembly and reassembly witha new divider block. The current invention allows a user to interchangeany of the sleeves and pistons without having to disconnect tubing linesand tube fittings from the divider block or dissemble the divider block.The sleeves 501 enter the piston bore 503. The sleeves are lined with aset of O-rings to stabilize and seal and separate the hydraulic circuitsand the sleeves in the divider block bore.

FIG. 6 shows a close-up model of sleeve and piston system 600. Sleeve601 is configured to fit pistons 602 in a precise fit. The manufactureof these materials can be steel or alloy as discussed above regardingthe body of the mono-block. The sleeve is sized to fit within the pistonbore 603. Once positioned inside the channel of piston bore 603, thesleeve sits comfortably on a bed of O-rings 604. Although this inventionpurports to remove the use of O-rings, it is the O-rings in the baseplate and divider block section that the invention eliminates the needfor. These O-rings traditionally ensured a seal within the base plateand divider block sections (not shown), but since no base plates arenecessary, no such O-rings are necessary. This area has in the past beena source of frequent problems that led to leaks under variousconditions. The invention of the mono-block eliminates the need tosecure leakages due to the design enabling the use of one solid piece ofmaterial.

The mono-block assembly provides many benefits. There is the ease andsimplicity of manufacturing one component (steel block) rather thanmultiple components that must be bolted together. Further, the amount ofpressure that the assembly can handle during the cycle of lubrication ismuch higher than the standard pressure. The mono-block is made from onepiece of material, such as steel, and the stress strain expansion isthus reduced. The replaceable sleeves and pistons allow for a moreefficient usage and ease of fixing during any type of malfunction. Andperhaps the largest benefit comes from the reduced cost and maintenancedue to the reusability of the divider block housing with interchangeablepistons and sleeves.

FIGS. 7A-7C show how sleeves 701 are interchangeable even within its ownsystem 700. Sleeve 701 fits within piston bore 702, 703, and 704. Theinterchangeability of these sleeves proves to have beneficial resultsthat far exceeded performance expectations when compared to othersimilar technology. Unlike previous systems that required thereplacement of the whole system during repairs, users are now onlyrequired to open the piston bore and replace the sleeve having a piston.This far reduces time, cost and efficiency of a production line andfield replacement.

In an industry that currently removes and disposes the divider blockswhen the pistons become worn and when pistons start to bypass, thecurrent invention is less wasteful and less costly to the end user. Thereplaceable sleeves and pistons are estimated to cost 75% less tomanufacture. Further, the disposal of the steel divider blocks createstons of waste steel that cannot be reused while replaceable sleeves andpistons would produce only a fraction of such waste.

The use of a monoblock divider also eliminates distortion in the pistonbore, which are often caused by over-tightening of the mounting bolts onindividual divider block sections. These mounting bolts often come withspecific directions directing users not to over-tighten, but the torquevalues are only 60 inch pounds which is very minimal so users have anatural tendency to tighten more than necessary, which always results inthe distortion in the piston bore. The monoblock divider also eliminatesleak paths caused by the use of O-ring seals which are used in allindustry standard divider blocks and allows for fewer machinedcomponents.

The configuration of the sleeves 701 and pistons allows for the user toreplace the internal piston and not the complete divider block. Itenables the operator to easily change the piston. It also has theability to reconfigure the output capacities of each individual piston.Each replaceable piston and sleeve assembly is replaceable with adifferent assembly with different output capacities. The size of thereplaceable pistons can be altered with different desired applications.Each sleeve combination 701 is designed and with specific sizes ofpistons to allow the accurate output of lubricant capacity and honedscientifically honed for piston to sleeve clearances of 80,000,000(millionths of an inch) to move back and forth with lubricant pressure.

According to one embodiment of the current invention and FIG. 8, a closeup of the replaceable sleeve 800 is shown. The stainless steel sleevehas a precise center cavity 801 that enables the piston to be honefitted to tolerances of 80 millionths of an inch. The sleeve 800 sitsprecisely within the divider block bore resting on a number of O-rings802.

FIG. 9 shows a system 900 in accordance with one embodiment of thecurrent invention wherein the alignment of the sleeve 901 is shown.

FIG. 10 shows a complete mono-block assembly 1000 shown with the insidecomponents. In accordance with the methods of using a monoblock dividerdescribed in this specification, a user can install a sleeve 1001 withthe piston 1002 into sleeve channels in the divider block 1003. Thesleeve 1001 and piston 1002 assembly comes with the lubricantpreinstalled on the sleeve, so no lubricant is needed. According to oneembodiment of the invention, the user then slides an O-ring compressorover the top of the sleeve 1001 assembly and tightens a wing nut on theO-ring compressor (not shown). The user then slides the sleeve 1001 intosleeve channel 1003 until it reaches the end of the divider block body.The sleeve 1001 sits firmly on the machined indention on the end of thedivider block body (not shown). Once that is finished, the user pusheson the end of the sleeve 1001 and piston 1002 assembly with a wooden rod(or some form of pushing device) until the sleeve 1001 and piston 1002assembly bottoms out on the opposite end of the divider block body. Asecond O-ring 1004 is sealed to the end plug 1005 and both end plugsreplaced. The O-ringed sleeve channel 1003 that houses the piston 1002is installed using a compression device that compresses the O-rings sothe operator can install the sleeve without cutting the O-rings. This issimilar to the compression device used to compress the rings on a pistonto eliminate breaking the piston rings in the automobile industry when amechanic is installing them in an engine block.

As shown by the end plug 1005, the exact alignment precision that isnecessary was traditionally made by fitting the pistons into an exactlyaligned piston tube. By using the sleeve system, the alignment is madeby the connection made between the piston and the sleeve and from theend plugs 1005. The end plugs 1005 tighten over the end of each of thesleeves. By connecting (either by screw or by physical alignment) theend plugs 1005 place the sleeve 1001 and the pistons 1002 in exactperfect alignment of the hydraulic circuit every time duringinstallation.

Because of the replaceable sleeve, there are no gaskets and no O-rings(except for the O-rings that seal the end plugs). This allows for a muchfaster and efficient method of repairing the divider block system andless likely to cause any type of error. In addition, the use of thesereplaceable piston/sleeves allows for the manufacture of only one sizepiston block housing. Conventional multiple divider blocks allows forabout 3000 psi of operating pressure due to stress strain expansion. Atmost, the current multiple divider blocks allow for about 3500 psi. Withthe use of the monoblock, operating pressures up to 8,000 psi can bereached.

Although the present invention and its advantages have been described indetail, it should be understood that various changes, substitutions andalterations can be made to the embodiments described herein withoutdeparting from the spirit and scope of the invention as defined by theappended claims. Moreover, the scope of the present application is notintended to be limited to the particular embodiments of the process,machine, manufacture, composition of matter, means, methods and stepsdescribed in the specification. As one of ordinary skill in the art willreadily appreciate from the disclosure of the present invention,processes, machines, manufacture, compositions of matter, means,methods, or steps, presently existing or later to be developed thatperform substantially the same function or achieve substantially thesame result as the corresponding embodiments described herein may beutilized according to the present invention. Accordingly, the appendedclaims are intended to include within their scope such processes,machines, manufacture, compositions of matter, means, methods, or steps.

We claim as follows:
 1. A divider block assembly for distributing a low volume of a lubricant at high pressure, the divider block being operated by the pressure of the lubricant being dispensed, comprising: one divider block made from a single integral and gaplessly continuous piece of material having; at least one inlet, at least one outlet, at least three piston bores, each piston bore sized to receive a replaceable sleeve, a replaceable sleeve with an outlet passage for lubricant, a piston in the replaceable sleeve which dispenses lubricant by the pressure of the incoming lubricant; and at least one end plug that is aligned with the replaceable sleeve.
 2. The divider block assembly of claim 1 wherein the divider block is made from stainless steel.
 3. The divider block assembly of claim 1 wherein the divider block is made from carbon steel.
 4. The divider block assembly of claim 1 wherein the divider block is made from composite.
 5. The divider block assembly of claim 1 wherein the replaceable sleeve comes in various lubricant output capacities, which can be replaced even after initial use.
 6. The divider block assembly of claim 1 wherein the end plugs connect with the sleeves further aligning the pistons with the flow of lubricant in the hydraulic circuit.
 7. The divider block assembly of claim 1 having an O-ring compressor over the sleeve assembly.
 8. A method of manufacturing a divider block comprising: collect one piece of material made from one type of metal or composite having at least one piston bore; use cast molding process to mold a single divider block body made of one material; make replaceable sleeves sized to fit at least one piston bore; and making a piston of various output capacities that can each fit into the replaceable sleeve.
 9. The method of claim 8 wherein the material is stainless steel.
 10. The method of claim 8 wherein end plugs are made that contain ends that fit precisely on the end of the sleeve that further align the pistons with the direction of the lubricant flow when the end plugs are tightened.
 11. A divider block for distributing a low volume of a lubricant at high pressure, the divider block being operated by the pressure of the lubricant being dispensed, comprising: a body having at least one inlet section, at least one outlet, channels connecting the inlets to outlets, wherein: pistons in sleeves located in the channels deliver particular quantities of lubrication at various, desired speeds and wherein the pistons are replaceable, and wherein the body of the divider block is resilient to changes made from tightening of bolts.
 12. The divider block assembly of claim 11 wherein the single material and single piece allows for liquid pressures up to 8,000 psi.
 13. A method of repairing a divider block assembly having a faulty piston comprising: installing a divider block made from one single piece of material; removing the faulty piston from a piston bore without disrupting the connections of other inlets and outlets that are connected to the divider block during use; replacing the faulty piston; and restarting the use of the divider block.
 14. The method of claim 13 wherein the replacement piston is further aligned by end plugs that are tightened once the replaceable piston is replaced.
 15. A method of changing the output capacity of a divider block comprising: installing a divider block that is not made from modular sections; removing a first piston from a piston bore without disrupting the connections of other inlets and outlets that are connected to the divider block during use; replacing the first piston with a second piston having a different output capacity; and starting the divider block.
 16. The method of claim 15 wherein the replacement piston is further aligned by end plugs that are tightened once the replaceable piston is replaced. 